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There exist several publications addressing and presenting an optimal design strategy for resonant LLC converters to end up with minimal ohmic losses. However, none of these papers takes unavoidable component tolerances into account. As a result, the specification cannot be met anymore for critical operation points. This paper proposes a new design strategy for resonant LLC converters, which incorporates these component tolerances. The resulting design provides minimal rms losses and guarantees the fulfillment of the converter specification under all circumstances at the same time.

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